Mazda Transaxle G35M–R. Manual — part 5
J–1
J
J
MANUAL TRANSAXLE
MANUAL TRANSAXLE. . . . . . . . . . .. J-2
PRECAUTION. . . . . . . . . . . . . .. J-2
5TH GEAR THRUST CLEARANCE
PREINSPECTION. . . . . . . . . . . . J-2
5TH/REVERSE GEAR AND HOUSING PARTS
DISASSEMBLY. . . . . . . . . . . . . J-3
5TH/REVERSE GEAR AND HOUSING PARTS
INSPECTION . . . . . . . . . . . . . J-6
CLUTCH HOUSING AND TRANSAXLE CASE
COMPONENTS DISASSEMBLY . . . . . .. J-8
PREINSPECTION. . . . . . . . . . ... J-12
DISASSEMBLY. . . . . . . . . . . ... J-13
INSPECTION . . . . . . . . . . . . .. J-14
ASSEMBLY. . . . . . . . . . . . . . J-16
PREINSPECTION. . . . . . . . . . ... J-18
DISASSEMBLY. . . . . . . . . . . ... J-20
INSPECTION . . . . . . . . . . . . .. J-21
ASSEMBLY. . . . . . . . . . . . . . J-24
DIFFERENTIAL PREINSPECTION . . . . ... J-27
DIFFERENTIAL DISASSEMBLY . . . . . ... J-28
DIFFERENTIAL ASSEMBLY . . . . . . . . J-29
BEARING PRELOAD ADJUSTMENT. . . . J-30
CLUTCH HOUSING AND TRANSAXLE CASE
COMPONENTS ASSEMBLY . . . . . . .. J-36
J–2
MANUAL TRANSAXLE
PRECAUTION
A6E511201029M01
1. Clean the transaxle exterior thoroughly using a steam cleaner or cleaning solvents before disassembly.
Warning
••••
Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eye wear whenever using compressed air.
Caution
••••
Cleaning sealed bearings using cleaning fluids or a steam cleaner can wash the grease out of the
bearing.
2. Clean the removed parts using cleaning solvent, and dry them using compressed air.
3. Clean out all holes and passages using compressed air, and check that there are no obstructions.
4. Use a plastic hammer when disassembling the transaxle case and other light alloy metal parts.
5. Make sure each part is cleaned before assembling.
6. Coat all movable parts with the specified oil.
7. Replace parts whenever required.
8. Remove old sealant from contact surfaces before applying new sealant.
9. Assemble the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after
assembly before filling the transaxle with transaxle oil.
Warning
••••
Although the stand has a self-locking brake system, there is a possibility that the brake may not
hold when the transaxle is held in a lopsided position on the stand. This would cause the transaxle
to turn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold
the rotating handle firmly when turning the transaxle.
End Of Sie
5TH GEAR THRUST CLEARANCE PREINSPECTION
A6E511201029M02
1. Remove the rear cover.
2. Measure the 5th gear thrust clearance using a
dial indicator.
•
If the clearance exceeds the maximum, check
the contact surfaces of 5th gear and the
clutch hub. Replace worn or damaged parts.
Clearance
0.100—0.220 mm {0.0040—0.0086 in}
Maximum
0.270 mm {0.0106 in}
End Of Sie
MANUAL TRANSAXLE
Z4F5112M001
MANUAL TRANSAXLE
J–3
J
5TH/REVERSE GEAR AND HOUSING PARTS DISASSEMBLY
A6E511201029M03
1. Disassemble in the order shown in the figure.
Caution
••••
If any old sealant gets into the transaxle during installation of the transaxle case, trouble may
occur in the transaxle. Remove any old sealant from the transaxle case and clutch housing, and
with cleaning fluids.
J–4
MANUAL TRANSAXLE
.
A6E5112M117
1
Rear cover
2
Locknut (primary shaft)
(See
J–5 Locknut Disassembly Note
3
Locknut (secondary shaft)
(See
J–5 Locknut Disassembly Note
4
5th/reverse shift fork
5
5th/reverse clutch hub component
6
5th synchronizer ring
7
5th gear
8
Gear sleeve
9
Secondary 5th gear
10
Lock bolt
11
Guide bolt
12
Lock bolt, ball, and spring
13
Back-up light switch
14
Neutral switch
15
Transaxle case component
16
Magnet
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